POINTEK CLS 200 OINTEK CLS 200 CAPACITANCE LIQUIDS/SOLIDS. Instruction Manual December 2001

Transcription

1 POINTEK CLS 200 CAPACITANCE LIQUIDS/SOLIDS Instruction Manual December 2001 OINTEK CLS 200

2 Safety Guidelines Warning notices must be observed to ensure personal safety as well as that of others, and to protect the product and the connected equipment. These warning notices are accompanied by a clarification of the level of caution to be observed. Qualified Personnel This device/system may only be set up and operated in conjunction with this manual. Qualified personnel are only authorized to install and operate this equipment in accordance with established safety practices and standards. Warning: This product can only function properly and safely if it is correctly transported, stored, installed, set up, operated, and maintained. Note: Always use product in accordance with specifications. Copyright Siemens Milltronics Process Instruments Inc All Rights Reserved This document is available in bound version and in electronic version. We encourage users to purchase authorized bound manuals, or to view electronic versions as designed and authored by Siemens Milltronics Process Instruments Inc. Siemens Milltronics Process Instruments Inc. will not be responsible for the contents of partial or whole reproductions of either bound or electronic versions. Disclaimer of Liability While we have verified the contents of this manual for agreement with the instrumentation described, variations remain possible. Thus we cannot guarantee full agreement. The contents of this manual are regularly reviewed and corrections are included in subsequent editions. We welcome all suggestions for improvement. Technical data subject to change. MILLTRONICS is a registered trademark of Siemens Milltronics Process Instruments Inc. Contact SMPI Technical Publications at the following address: Technical Publications Siemens Milltronics Process Instruments Inc Technology Drive, P.O. Box 4225 Peterborough, Ontario, Canada, K9J 7B1 techpubs@siemens-milltronics.com For the library of SMPI instruction manuals, visit: Siemens Milltronics Process Instruments Inc. 2001

3 Table of Contents Introduction to the Pointek CLS Pointek CLS 200 Outputs...2 Pointek CLS 200 Features...2 Pointek CLS 200 Applications...2 Specifications...3 Installation...5 Location...5 Dimensions...6 CLS 200 Versions...6 Mounting...9 Installation Features and Restrictions...9 Process Cautions...11 Interconnection...12 Relay Output Connection...13 Solid State Switch...13 Ancillary 2-Wire Output Connection...14 Power Connection...14 Operation...15 Setup...15 Dip Switch Dip Switch Dip Switch Dip Switch Dip Switch Start Up...16 Indicators...16 Alarm Output...17 Alarm Output Status...17 Setpoint Adjustment...17 Troubleshooting...20 Maintenance...20 Appendix 1: Shortening the Cable...21 Appendix 2: Approvals...24 Index ML19985AR01 Pointek CLS 200 Page 1

4 Introduction to the Pointek CLS 200 Note: Pointek CLS 200 is only to be used in the manner outlined in this instruction manual. The Pointek CLS 200 capacitance level switch provides output on high or low process material levels. When the measured material approaches or contacts the switch's probe, an increase in capacitance is sensed triggering a high level alarm. If low level monitoring is required, then the lack of material contact is sensed, triggering the low level alarm. Pointek CLS 200 Outputs One form C (SPDT) relay One open isolated, non-polarized, solid-state switch Pointek CLS 200 Features NPT, BSP, and 3A compliant Tri-clamp connections (other connections on request) Corrosion resistant construction, Kynar, and 316 stainless steel wetted parts 35m (115 ft) maximum insertion length Fully adjustable process alarm (level, time delay, and fail-safe mode) Rigid extensions of standard and sanitary versions Cable version with customizable length Pointek CLS 200 Applications Liquids, slurries, powders, granules, and solids Foods and pharmaceuticals Chemical and petrochemical High pressure and temperature Page 2 Pointek CLS 200 7ML19985AR01

5 Specifications Power V ac/dc 50/60 Hz 2 VA / 2 W max Environmental location: indoor/outdoor altitude: 2000m max ambient temperature: -40 to 85 C (-40 to 185 F) relative humidity: suitable for outdoor (Type 4X / NEMA 4X / IP65) installation category: II pollution degree: 4 Process dielectric constant (εr): temperature: pressure: 1.5 min -40 to 125 C (-40 to 257 F) standard and rigid extension versions 0 to 25 bar / 365 p.s.i. / 2500 kpa gauge (nominal) cable version 0 to 10 bar / 150 p.s.i. / 1000 kpa gauge (nominal) Alarm Output relay: 1 form C (SPDT) contact, rated 8A at 250V ac / 5A at 30V dc, non-inductive solid state switch: rated 250V ac / 300V dc, 100mA max (2VA max.) time delay: ON/OFF alarm selectable, 1 to 60 seconds adjustable hysterisis: 2mm (0.08") repeatability: 2mm (0.08") fail-safe operation (high or low) Electronics/Enclosure termination: construction: ingress protection: electrical: removable terminal block, 2.5mm 2 max epoxy coated aluminum with gasket (optional thermal isolator, 316 stainless steel) Type 4X / NEMA 4X / IP65 2 x 1/2" NPT conduit entry 7ML19985AR01 Pointek CLS 200 Page 3

6 Probe Length (max) Standard 5.5m (18ft) ¾ " NPT, 1" BSPT, 1 ½ BSPT 316 stainless steel Sanitary 5.5m (18ft) 1", 1 ½ ", and 2"; 3A compliant triclamp Cable 35m (115ft) ¾ " NPT, 1" BSPT, 1 ½ BSPT 316 stainless steel Mounting 1 Extension Tensile (max) Sensor 316 stainless n/a Kynar 2 steel 316 stainless steel Kynar 3 n/a Kynar 2 180kg (400 lbs) Kynar 2 Approvals CE, CSA NRTL/C FM, CENELEC, 3A. Please verify against device nameplate. 1 Other process connections available on request. 2 Option: P.P.S. (Polyphenylen Sulfide) 3 Kynar is a registered trademark of ELF Atochem. For a chemical resistance list for Kynar, contact your local distributor. Page 4 Pointek CLS 200 7ML19985AR01

7 Installation Location Notes: Installation shall only be performed by qualified personnel and in accordance with local governing regulations. This product is susceptible to electrostatic shock. Follow proper grounding procedures. The Pointek CLS 200 standard probe length is normally mounted into the vessel top (high detection alarm) or through the tank wall at the detection level (high or low detection alarm). The extended versions are designed for top mounting. The probe suspends vertically so that it reaches into the process at the desired detection level (high or low detection alarm). Vertical Angle Horizontal 7ML19985AR01 Pointek CLS 200 Page 5

8 Dimensions CLS 200 Versions Standard 145mm* (5.7") Lid Electronics/ Enclosure 120mm (4.7") Probe/Sensor** 120mm (4.7") 76mm (3") ½" NPT Lid Clip 59mm (2.3") Standard with Thermal Isolator 245mm* (9.7") 120mm (4.7") Thermal Isolator Sensor Probe** Note: * Nominal Values ** Wetted parts are Kynar and 316 stainless steel Page 6 Pointek CLS 200 7ML19985AR01

9 Standard with Extension 145mm* (5.7") 5.5m (18 ft) Max Extension Sensor 20mm (0.8") Ø Probe** Sanitary Lid 165mm* (6.5") Electronics/ Enclosure 100mm* (3.9") Probe/Sensor** 76mm (3") 120mm (4.7") Sanitary Tri- Clamp ½ " NPT Lid Clip 59mm (2.3") Note: * Nominal Values ** Wetted parts are Kynar and 316 stainless steel 7ML19985AR01 Pointek CLS 200 Page 7

10 Sanitary with Extension 165mm* (6.5") 5.5m (18ft) Max Extension Sensor 23mm (0.9") Probe** Cable Lid ½ " NPT Electronics/Enclosure 120mm (4.7") 76mm (3") Flexible Extension ** Cable! Lid Clip 59mm (2.3") Sensor Weight Note: * Nominal Values ** Wetted parts are Kynar and 316 stainless steel.! To shorten cable for setting sensor at required alarm point, see Appendix 1 on page 21. Probe** 20mm (0.8") Ø Sensor Page 8 Pointek CLS 200 7ML19985AR01

11 Mounting Installation Features and Restrictions Please note the following installation features and restrictions to ensure that your unit operates properly. Standpipes < 50mm (2") > 100mm (4") Ø Multiple Units End View Side View 100mm (4") Min 100mm (4") Min 100mm (4") Min Sensors must be 100mm apart. Mount diagonally if vertical space is restricted. 7ML19985AR01 Pointek CLS 200 Page 9

12 Wall Restrictions 50mm (2") Min 50mm (2") Min Page 10 Pointek CLS 200 7ML19985AR01

13 Process Cautions Caution: Keep unit out of path of falling material. Caution: Consider material surface configuration when installing unit. Caution: Protect probe from falling material. Caution: Tensile load must not exceed probe or vessel rating. 50mm (2") Min Caution: Avoid areas where material build up occurs. 7ML19985AR01 Pointek CLS 200 Page 11

14 Interconnection Loosen the lid clip and remove the lid to access the connectors and electronics. The identification label is on the underside of the lid. Please note the following: Relay contact terminals are for use with equipment having no accessible live parts and wiring having insulation suitable for at least 250V. Maximum working voltage between adjacent relay contacts is 250V. Max: 2VA Note: Switch and potentiometer settings are for illustration purposes only. All field wiring must have insulation suitable for at least 250V. Page 12 Pointek CLS 200 7ML19985AR01

15 Relay Output Connection The relay is shown in a de-energized state. K2 contact ratings: 8A at 250V ac 5A at 30V dc Solid State Switch Solid state switch to customer's control or instrumentation device. Switch shown in de-energized state. K3 contact ratings: 250V ac, 100mA max., nonpolarized (max. 2VA) 300V dc, 100mA max, nonpolarized (max. 2VA) Note: When driving an external relay with either the solid state switch and/or relay outputs using dc power, protection diodes must be connected in the correct polarity to prevent possible switch/relay damage resulting from inductive spikes generated by the relay coil. Diode Protection When driving an external relay with either the solid stated switch and/or relay outputs using dc power, protection diodes must be connected in the correct polarity across the relay coil to prevent possible switch/relay damage resulting from inductive spikes generated by the relay coil. Switch capacity: 250V ac 100mA max. 2VA/2W max relay coil 300V dc. 100mA max. 2VA/2W max Customer supplied diode protection 7ML19985AR01 Pointek CLS 200 Page 13

16 relay coil Customer supplied diode protection Ancillary 2-Wire Output Connection (See below) Output Optically isolated switch. (Customer supplied; we suggest Phoenix DEK-OE-5DC/48DC/100 or equivalent.) V dc (See Power Connection below) Power Connection Nominal 24 V dc 48 V dc V dc V V R 120 Ω 234 Ω V AC/DC Page 14 Pointek CLS 200 7ML19985AR01

17 Operation Setup Note: Setup can be done in the field with the Pointek CLS mounted into process, or in the shop prior to mounting. Dip Switch 1 Set ON to open the alarm relay immediately when the sensor detects a change in contact. Use this setting when time is critical. Set OFF to keep the alarm relay closed by the amount set on potentiometer #1 (P1). Use this setting when you want to slow the response to account for turbulence or false readings. Dip Switch 2 Set ON to open the alarm relay immediately when the sensor detects a change in contact. Use this setting when you need the alarm to stop as soon as the contact state changes. Set OFF to keep the alarm relay closed by the amount of time set on potentiometer #1 (P1). Use this setting when you want to avoid false or early alarm relay cut-outs due to turbulence or false readings. Dip Switch 3 Set ON for fail-safe high alarm. Set OFF for fail-safe low alarm. Dip Switch 4 Set ON to test the delay of the alarm relays as set by the potentiometer #1 (P1). Set OFF for normal operation. 7ML19985AR01 Pointek CLS 200 Page 15

18 Dip Switch 5 Set ON for normal sensitivity on the sensor. Use this setting for measuring dry solids or nonconductive liquids. Set OFF for low sensitivity on the sensor. Use this setting for measuring conductive liquids or wet conductive solids that can build up. Delay: Alarm OFF Delay: Alarm ON Fail-safe Delay test Sensitivity Switches shown in OFF position. Delay ON Delay OFF Fail Safe Delay Test Sensivity SI-1 SI-2 SI-3 SI-4 SI-5 ON disabled disabled high test normal OFF enabled enabled low normal low Start Up After the CLS is properly mounted and the switch bank is set up, apply power to the unit. The green LED (L3) lights up to indicate the unit is powered and operational. Indicators Three LEDs indicate the following: L1 (yellow) = sensor status: When P2 is properly set, this LED indicates when the sensor is in contact with the process material (material capacitance is greater than the setpoint, P2). L1 is off when the sensor is out of contact with the process material (material capacitance is less than the setpoint). L2 (red) = output status: L3 (green) = power: This LED indicates relay and solid switch contact status. Refer to Operation/Output Status below. This LED is on when the Pointek CLS is properly powered. Page 16 Pointek CLS 200 7ML19985AR01

19 Alarm Output Alarm Output Status High Alarm Low Alarm Setpoint Adjustment As reference, and to assist in adjusting the alarm setpoint for reliable and accurate detection of the process material, we have classified the materials and applications into three cases. Follow the setup procedure for the case outline describing your application. Case 1: General applications, characterized by the following: dry solids low viscosity liquids Case 2: Demand applications, characterized by the following: hygroscopic / wet solids high viscosity and high conductivity liquids Case 3: Interface detection: e.g. liquid A / liquid B, foam / liquid 7ML19985AR01 Pointek CLS 200 Page 17

20 Trip point Switches Delay Output status (red) Sensor status (red) Power (green) Case 1 Preparation Ensure that L3 (green) is ON Turn both potentiometers, P1 and P2, fully CCW (counterclockwise) Set S1 switches 1 to 4 to OFF and S1 switch 5 to ON (normal sensitivity) Configuration 1. With sensor uncovered and a minimum 100mm free space all around, turn P2 CW (clockwise) until L1 (yellow) turns ON. 2. Turn P2 CCW until L1 goes OFF. Case 2 Preparation Ensure that L3 (green) is ON Turn potentiometer P1 fully CCW (counterclockwise) Turn potentiometer P2 fully CW (clockwise) Set S1 switches 1 to 4 to OFF and S1 switch 5 to OFF (low sensitivity). Configuration 1. Adjust the material level of the process so that the sensor is immersed, L1 (yellow) should be ON. If L1 does not light, reset S1 switch 5 to ON (back to normal sensitivity; the appropriate position of S1 switch 5 depends on the dielectric properties of the material). 2. Adjust the material level of the process so that the sensor is uncovered, but retains a significant (as much as possible) build up of material on the sensor. 3. Adjust P2 CCW until L1 OFF. To get the true feel for the correct position, please adjust P2 CW then CCW several times to ensure that L1 is OFF. (This adjustment is very sensitive, and we recommend this practice exercise so you can fine tune P2 until L1 turns OFF with minimal adjustment.) Page 18 Pointek CLS 200 7ML19985AR01

21 Case 3 Preparation Ensure that L3 (green) is ON Turn potentiometer P1 fully CCW (counterclockwise) Turn potentiometer P2 fully CW (clockwise) Set S1 switches 1 to 5 to OFF Configuration 1. Immerse the sensor in the material that has the lowest dielectric constant. L1 (yellow) should be ON. If not, S1 switch 5 should be set to ON (normal sensitivity). 2. Adjust P2 CCW until L1 goes OFF. 3. Immerse the sensor in the material that has the highest dielectric constant. L1 should come ON. Delay The alarm actuation can be delayed for either or both ON ALARM and OFF ALARM conditions. The selection is made by setting S1-1 and S1-2. (Refer to Setup/Switch Bank on page 15.) Adjust the delay time from 1 to 60 seconds by setting potentiometer P1. Operation After completing the setup, replace the Pointek CLS lid and lid clip. The unit is now in service, providing level detection of your process. 7ML19985AR01 Pointek CLS 200 Page 19

22 Troubleshooting Symptom Observation Action No Alarm Response L3 (green) off Check power supply L1 (yellow) doesn't respond to uncovering the sensor Alarm doesn't switch when sensor is uncovered Alarm doesn't switch on when sensor is covered L1 (yellow) responds to uncovering the sensor L1 doesn't respond to covering the sensor Check sensitivity S1-5 sensor (and zener barrier if used) Check that relay changes state when S1-3 is toggled. Check sensitivity S1-5 sensor (and zener barrier if used) L1 responds to covering the sensor Check that relay changes state when S1-3 is toggled. L1 flashes when approaching the alarm setpoint Maintenance The Pointek CLS requires no maintenance or cleaning. Page 20 Pointek CLS 200 7ML19985AR01

23 Appendix 1: Shortening the Cable Caution: Allowed in general purpose version only; please verify against device nameplate. Preparation Measure the actual length of the cable and subtract the required length to determine the amount to be cut off in step 5. e.g. actual length 10 m desired length - 9 m excess = 1m Actual length Required length Excess length Steps 1. Unscrew the cable gland compression nut to relieve the compression ferrule and release the cable. Cable gland, compression nut Sleeve Probe, lower assembly 7ML19985AR01 Pointek CLS 200 Page 21

24 2. Unscrew the probe sleeve from the lower assembly using two wrenches (17mm) across the flats, exposing the leads (3), the spacer, and the tension block. Stainless Steel Spacer Tension Block Connection 3. Remove the insulation covering the solder connections. 4. Unsolder the connections. Note: Do not cut the connection to the probe leads, as this can render them too short to work with later. 5. Remove the sheathing around the tension block, and then remove the block for re-use in step Cut off the excess cable. 7. Remove approximately 6cm (2.4") of cable jacket, shield, and filler strands. 8. Replace the tension block and shorten the lead to approximately 4cm (1.6"). 9. Prepare the leads for soldering. Note: If heat shrink is used to insulate splices and sheath the tension block (steps 9 and 11), remember to slip them on before soldering the leads. Page 22 Pointek CLS 200 7ML19985AR01

25 10. Make the solder connections and insulate. 5cm (2") Stainless Steel Spacer Tension Block Core 11. Remove the excess core. 12. Sheath the tension block. 13. Re-dress the probe sleeve thread with Teflon tape or sealant. 14. Reassemble the sleeve and cable gland. Insure that the cable is not turned excessively, as this could break the leads. 15. Check unit for proper operation. 7ML19985AR01 Pointek CLS 200 Page 23

26 Appendix 2: Approvals WRITTEN DECLARATION OF CONFORMITY We, Siemens Milltronics Process Instruments B.V. Nikkelstraat AB BREDA - The Netherlands Declare, solely under own responsibility, that the product Point Level Switch, Pointek CLS 200 Mentioned in this declaration, complies with the following standards and/or normative documents: Requirements Remarks Certificate No Environment Commercial, light Industrial and industrial KRQ/EMC EN 61326: 1998 EN 55011: 1998 EN : 1995 EN : 1996 EN : 1995 EN : 1995 EN : 1996 Product group standard for Electrical equipment for measurement, control and laboratory use, from which: Emission Class B Electrostatic Discharge (ESD) Immunity Radiated Electro-Magnetic Field Immunity Electrostatic Fast Transient (EFT) Immunity Surge Transient Immunity Conducted Radio-Frequency Disturbances Immunity ATEX Directive 94/9/EC Audit Report No KEMA 00ATEXQ3047 I 1/ 2 GD EEx d [ia] IIC T6 T KEMA 00ATEX2039X T 100 C IP 66 EN 50014: 1992 EN 50018: 1994 EN 50020: 1994 EN 50284: 1999 EN : 1998 General Requirements Flameproof Enclosures d Intrinsic Safety i Special Requirements for Category 1G Equipment Dust Ignition Proof Notified body: N.V. KEMA Utrechtseweg AR Arnhem The Netherlands 97/23/EC Pressure Equipment Directive Lloyd s Register, DAD No.: , , Notified body: Stoomwezen B.V. Weena Zuid NC Rotterdam The Netherlands Location: Breda Representative Name: C.S. van Gils Date: August 31, 2001 Function: Managing Director Remark: For specific safety specifications, please consult the instrument label. Page 24 Pointek CLS 200 7ML19985AR01

27 Index A Alarm Output...5 Alarm Output Status...19 Ancillary 2-Wire Output Connection...16 Angle 7 Applications...4 Approvals...6, 26 C Cable...10 CLS 200 Versions Standard...8 D Dip Switch Dip Switch Dip Switch Dip Switch E Electronics/Enclosure...5 Environmental...5 F falling material...13 Features...4 H Horizontal...7 I Indicators...18 Installation Features and Restrictions...11 Interconnection...14 K K2 contact ratings...15 K3 contact ratings...15 L Location...7 M Maintenance...22 Multiple units...11 O Outputs...4 P Power...5 Power Connection...16 Probe...6 Process...5 Process Cautions...13 R Relay Output Connection...15 S Sanitary...9 Sanitary with Extension...10 Setpoint Adjustment...19 Setup...17 Shortening the Cable...23 Solid state switch...15 Standard with Extension...9 Standard with Thermal Isolator...8 Standpipes...11 Start Up...18 T tension block...24 Troubleshooting...22 V Vertical...7 W Wall Restriction ML19985AR01 Pointek CLS 200 Page 25

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29 Notes

30 Notes

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32 Rev. 1.2